Methods for printer cartridge modification

ABSTRACT

Techniques are provided for modifying a printer cartridge intended for installation in one type of printer to be installed in another type of printer or a plurality of printers. In one aspect, a method of modifying a toner cartridge may include modifying one or more end caps of the toner cartridge. In another aspect, a method of modifying a toner cartridge may include replaced one or more end caps of the toner cartridge with replacement end caps.

BACKGROUND

The present invention relates to remanufacturing and modifying imagingprocess cartridges, such as printer toner cartridges, and moreparticularly to techniques for modifying an imaging process cartridgeintended to operate in one type of imaging device, such as a printer, tooperate in additional types of imaging devices.

In the printing industry, there is a growing market for theremanufacture and refurbishing of various types of imaging componentssuch as toner cartridges, ink cartridges, magnetic rollers, seals, andthe like. Toner cartridges, once spent, are unusable for theiroriginally intended purpose. Without a refurbishing process, they wouldsimply be discarded, even though the cartridge itself may still havepotential life. As a result, techniques have been developed specificallyto address this issue. These processes may entail, for example, thedisassembly of the various structures of the cartridge, replacing toner,cleaning, adjusting or replacing any worn components and reassemblingthe cartridge.

The differences between printer cartridges for various types of printingdevices may only be slight or subtle. In many instances it may only bean indentation or protuberance in the body of the cartridge. In othercases it may be not only a physical attribute of the body of thecartridge, but also the addition of a communications device. Certainstyle cartridges may be plentiful and relatively inexpensive simplybecause of certain factors such as the supply in the market or initialcost while other style cartridges may not be available in quantity ortoo expensive for cost effective use in remanufacturing. The easiest andmost economic solution would be to simply convert the inexpensive stylecartridges into the more costly style cartridge in order to meet thismarket demand. Additionally, it would be desirable to convert acartridge into a type of cartridge that can be used in many differentprinter types.

SUMMARY

In accordance with an embodiment of the present invention, techniquesare provided for modifying a printer cartridge intended to operate inone type of printer to operate in another type of printer or operate ina plurality of types of printers.

In one aspect of the present invention, a method of modifying an imagingprocess cartridge, the imaging process cartridge sized to be installedin a first type of imaging device and not sized to be installed in asecond type of imaging device, includes: providing the imaging processcartridge comprising a cartridge body and a gear side end plate attachedto the cartridge body, said gear side end plate comprising a generallyelongated shape having a generally curved first end, a generally planarsecond end and a limiting projection element disposed substantiallyequidistant the first end and the second end, the limiting projectionelement extending outward from said gear side end plate; removing thegear side end plate from the cartridge body; providing a replacementgear side end plate comprising a generally longitudinal shape having agenerally curved first end and a generally planar second end, thereplacement gear side end plate not comprising a limiting projectionelement disposed substantially equidistant the first end and the secondend; and attaching the replacement gear side end plate to the cartridgebody to form a modified imaging process cartridge.

In another aspect of the present invention, a method of modifying animaging process cartridge, the imaging process cartridge sized to beinstalled in a first type of imaging device and not sized to beinstalled in a second type of imaging device, includes: providing theimaging process cartridge comprising a cartridge body and a gear sideend plate attached to the cartridge body, the gear side end platecomprising a generally elongated shape having a generally curved firstend, a generally planar second end and a limiting projection elementdisposed substantially equidistant the first end and the second end, thelimiting projection element extending outward from said gear side endplate; and removing said limiting projection element extending outwardfrom said gear side end plate and disposed substantially equidistant thefirst end and the second end to form a modified imaging processcartridge, said modified imaging process cartridge sized to be installedin both the first type of imaging device and the second type of imagingdevice

A more complete understanding of the present invention, as well asfurther features and advantages of the invention, will be apparent fromthe following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a first prior art toner cartridgewith the gear side in the foreground;

FIG. 2 shows a perspective view of a second prior art toner cartridgewith the contact side in the foreground;

FIG. 3 shows a frontal view of the gear side end cap of the first priorart toner cartridge;

FIG. 4 shows a frontal view of a universal gear side end plate inaccordance with the present invention;

FIG. 5 shows a rear view of the universal gear side end plate of FIG. 4in accordance with the present invention;

FIG. 6 shows a frontal view of the contact side end plate of the secondprior art toner cartridge;

FIG. 7 shows a rear view of the contact side end plate of the secondprior art toner cartridge; and

FIG. 8 shows a frontal view of a universal contact side end plate inaccordance with the present invention.

DETAILED DESCRIPTION

The following detailed description of preferred embodiments refers tothe accompanying drawings which illustrate specific embodiments of theinvention. In the discussion that follows, specific techniques forconverting an imaging process cartridge, such as a toner printercartridge, for installation into one or more different types of printersare disclosed. Other embodiments having different structures andoperations for the conversion of other types of cartridges for use withother types of printers do not depart from the scope of the presentinvention.

FIG. 1 shows a perspective view of a prior art toner cartridge 100,specifically a cartridge suitable for use in an HP4300 laser printer.The cartridge 100 includes a cartridge body 102 attached to a gear sideend plate 104 and a contact side end plate 106. The gear side end plate104 is attached to the cartridge body 102 by a plurality of screws 116.The gear side end plate includes a limiting projection element 120 and aslide-shaped member 122. The cartridge body 102 includes a toner hopperportion 108, a magnetic roller holding portion 110 and a waste binportion 112. The cartridge 100 also includes an electronic circuit 114adapted for communication with the printer when the toner cartridge 100is installed in the printer.

Other types of laser printers, such as the HP4250 and HP4350 laserprinters, for example, utilize a toner cartridge with many similarities,but also with one or more differences which prevent an unmodified HP4300toner cartridge from being installed or operating in such otherprinters. Certain modifications can be made to HP4300 toner cartridge toallow the modified toner cartridge to be installed in additional printertypes.

FIG. 2 shows a perspective view of a prior art toner cartridge 200,specifically a cartridge suitable for use in an HP4350 laser printer.The cartridge 200 includes a cartridge body 202 attached to a gear sideend plate 204 and a contact side end plate 206. The contact side endplate 206 is attached to the cartridge body 202 by screws 216 and welds218, and includes copper contacts 220 for receiving signals from theprinter. The cartridge body 202 includes a toner hopper portion 208, amagnetic roller holding portion 210 and a waste bin portion 212. Thecartridge 100 also includes an electronic circuit 214 adapted forcommunication with the printer when the toner cartridge 200 is installedin the printer.

Other types of laser printers, such as the HP4200, HP4300 and HP4345laser printers, utilize a toner cartridge with many similarities, butalso with a few important differences which prevent an unmodified HP4350toner cartridge from operating in such other printers. Certainmodifications can be made to HP4350 toner cartridge to allow themodified toner cartridge to be installed in additional printer types

FIG. 3 shows a front view of the gear side end plate 104 of the tonercartridge 100. The gear side end plate 104 is generally elongated inshape and has a generally curved end 300 and a generally planar end 302.The limiting projection element 120 is disposed substantiallyequidistant the generally curved end 300 and the generally planar end302. As seen in FIGS. 1 and 3, the limiting projection element 120 isgenerally rectangular in shape and extends outward from the gear sideend plate 104. The slide-shaped member 122 is adjacent to the limitingprojection element 120 and comprises a horizontal wall 122 a and anangled portion 122 b. The limiting projection element 120 and theslide-shaped member 122 of the toner cartridge 100 prevent the tonercartridge 100, intended for use in the HP 4300 type of printer, frombeing installed in other printer types, such as the HP 4250 and the HP4350, for example.

FIGS. 4 and 5 show respectively a frontal view and a rear view of auniversal gear side end plate 400 in accordance with the presentinvention. As described in greater detail below, the universal gear sideend plate 400 may be formed by fabricating a new universal gear side endplate or modifying an existing gear side end plate 104. The universalgear side end plate 400 is generally elongated in shape and has agenerally curved end 402 and a generally planar end 404. Unlike the gearside end plate 104, the universal gear side end plate 400 does notinclude the limiting projection element 120. Additionally, the universalgear side end plate 400 includes a modified slide-shaped member 422which does not extend as far outward as the slide-shaped member 122.FIG. 5 also shows a plurality of axle rods and gears attached to theaxle rods.

By removing the gear side end plate 104 from the toner cartridge 100 andreplacing it with the universal gear side end plate 400, the tonercartridge 100 may be modified to allow the toner cartridge 100 to beinstalled in additional types of printers. The gear side end plate 104may be removed by unscrewing the screws 116 described above.Additionally, to ensure that the toner cartridge 100 with the universalgear side end plate 400 is readily installed in the additional printertypes, it may be desirable to remove a small portion of the tonercartridge 100 in the area adjacent where the limiting projection element120 and the slide-shaped member 122 were located prior to theinstallation of the universal gear side end plate 400. This area may beremoved with a file, knife, or other type of cutting tool, for example.Additionally, the electronic circuit 114, which was adapted forcommunication with only the first printer type, may be replaced with areplacement electronic circuit which is adapted for use with all theprinter types. The replacement electronic circuit may be PrintDetect™chip available from Static Control Components, Inc.

The universal gear side end plate 400 may be formed by fabricating, byinjection molding for example, a new end plate conforming to the sizerequirements of the universal gear side end plate 400. Alternatively,the gear side end plate 104 may removed from the toner cartridge 100 andmodified to form the universal gear side end plate 400. To perform sucha modification, the limiting projection element 120 and a portion of theslide-shaped member 122 should be removed. The removal of these portionsmay be accomplished by using a knife, a RotoZip® cutter or the like, forexample. To ensure an accurate cut, a jig may be used to correctlyposition and guide the RotoZip® cutter along a guide path to performthis removal.

FIG. 6 shows a frontal view of the contact side end plate 206 of thetoner cartridge 100. The contact side end plate 206 is generallyelongated in shape and has a generally curved end 600 and a generallyplanar end 602. The generally planar end 602 comprises a first wall 604and a second wall 606 intersecting at substantially right angles. Athird wall 608 located at substantially right angles to the first wall604 and the second wall 606 includes an aperture 610 adapted for holdingthe axle of an organic photoconductor (OPC) drum. The aperture 610 islocated at a first predetermined distance L1 from the first wall 604.The first wall 604 and portions of the second wall 606 and third wall608 of the toner cartridge 200 prevent the toner cartridge 200, intendedfor use in the HP 4350 type of printer, from being installed in otherprinter types, such as the HP 4300 and the HP 4345, for example.

FIG. 8 shows a frontal view and a universal contact side end plate 800in accordance with the present invention. As described in greater detailbelow, the universal contact side end plate 800 may be formed byfabricating a new universal contact side end plate or modifying anexisting contact side end plate 206. The universal contact side endplate 800 is generally elongated in shape and has a generally curved end802 and a generally planar end 804. The generally planar end 804comprises a first wall 806 disposed at a substantially right angle to asecond wall 808. A third wall 810 intersects, at substantially rightangles, the first wall 806 and the second wall 808 and includes anaperture 812 adapted for holding the axle of an organic photoconductor(OPC) drum. The aperture 812 is located at a predetermined distance L2from the first wall 806. The distance L2 is less than the distance L1.Unlike the contact side end plate 206, the first wall 806 and the secondwall 808 of the universal contact side end plate 800 do not intersect. Adiagonal member 814 connects the first wall 806 and the second wall 808.These differences from the contact side end plate 206 removeobstructions which prevent a cartridge utilizing the universal contactside end plate 800 to be installed in additional printer types.

By removing the contact side end plate 206 from the toner cartridge 200and replacing it with the universal contact side end plate 800, thetoner cartridge 200 may be modified to allow the toner cartridge 200 tobe installed in additional types of printers. The contact side end plate206 may be removed by breaking the welds 218, described above.Additionally, the electronic circuit 214, which was adapted forcommunication with only the first printer type, may be replaced with areplacement electronic circuit which is adapted for use with manyprinter types. The replacement electronic circuit may be PrintDetect™chip available from Static Control Components, Inc.

The universal contact side end plate 800 may be formed by fabricating,by injection molding for example, a new end plate conforming to the sizerequirements of the universal contact side end plate 800. Alternatively,the contact side end plate 206 may removed from the toner cartridge 200and modified to form the universal contact side end plate 400. Toperform such a modification, the first wall 604 and portions of thesecond wall 606 and the third wall 608 should be removed. The removal ofthese portions may be accomplished by using a knife, a RotoZip® cutteror the like, for example. To ensure an accurate cut, a jig may be usedto correctly position and guide the RotoZip® cutter along a guide pathto perform this removal. FIG. 7 shows a rear view of the contact sideend plate 206 with the portion 250 to be removed indicated by dashedlines. This removal exposes the underlying walls 252 and 254 whichbecome, respectively, the first wall 806 and the diagonal member 814 inthe universal contact side end plate 800.

Although specific embodiments have been illustrated and describedherein, those of ordinary skill in the art appreciate that anyarrangement which is calculated to achieve the same purpose may besubstituted for the specific embodiments shown and that the inventionhas other applications in other environments. This application isintended to cover any adaptations or variations of the presentinvention. The following claims are in no way intended to limit thescope of the Invention to the specific embodiments described herein.

1. A method of modifying an imaging process cartridge, the imagingprocess cartridge sized to be installed in a first type of imagingdevice and not sized to be installed in a second type of imaging device,the method comprising: providing the imaging process cartridgecomprising a cartridge body and a gear side end plate attached to thecartridge body, said gear side end plate comprising a generallyelongated shape having a generally curved first end, a generally planarsecond end and a limiting projection element disposed substantiallyequidistant the first end and the second end, said limiting projectionelement extending outward from said gear side end plate; removing thegear side end plate from the cartridge body; providing a replacementgear side end plate comprising a generally longitudinal shape having agenerally curved first end and a generally planar second end, saidreplacement gear side end plate not comprising a limiting projectionelement disposed substantially equidistant the first end and the secondend; and attaching the replacement gear side end plate to the cartridgebody to form a modified imaging process cartridge.
 2. The method ofclaim 1 further comprising: removing a portion of the cartridge body inthe area adjacent the location previously occupied by the limitingprojection element, wherein said modified imaging process cartridge issized to be installed in both the first type of imaging device and thesecond type of imaging device.
 3. The method of claim 1 wherein thelimiting projection element comprises a generally rectangular shape. 4.A method of modifying an imaging process cartridge, the imaging processcartridge sized to be installed in a first type of imaging device andnot sized to be installed in a second type of imaging device, the methodcomprising: providing the imaging process cartridge comprising acartridge body and a gear side end plate attached to the cartridge body,said gear side end plate comprising a generally elongated shape having agenerally curved first end, a generally planar second end and a limitingprojection element disposed substantially equidistant the first end andthe second end, said limiting projection element extending outward fromsaid gear side end plate; and removing said limiting projection elementextending outward from said gear side end plate and disposedsubstantially equidistant the first end and the second end to form amodified imaging process cartridge, said modified imaging processcartridge sized to be installed in both the first type of imaging deviceand the second type of imaging device.
 5. The method of claim 4 furthercomprising, before removing the limiting projection element: removingthe gear side end plate from the cartridge body.
 6. The method of claim5 further comprising, after removing said limiting projection element:attaching the gear side end plate to the cartridge body.
 7. A method ofmodifying an imaging process cartridge, the imaging process cartridgesized to be installed in a first type of imaging device and not sized tobe installed in a second type of imaging device, the method comprising:providing the imaging process cartridge comprising a cartridge body anda contact side end plate attached to the cartridge body, said contactside end plate comprising a generally elongated shape having a generallycurved first end and a generally planar second end, said generallyplanar second end comprising a first wall and a second wall intersectingat right angles, said generally planar second end comprising an aperturein a third wall adapted for holding an axle of an organic photoconductor(OPC) drum and located at a first predetermined distance from the firstwall; removing the contact side end plate from the cartridge body;providing a replacement contact side end plate comprising a generallylongitudinal shape having a generally curved first end and a generallyplanar second end, said generally planar end of the replacement contactside end plate comprising a first wall and a second wall disposed atright angles and not intersecting, said generally planar second end ofthe replacement contact side end plate comprising an aperture in a thirdwall adapted for holding an axle of an organic photoconductor (OPC) drumlocated at a second predetermined distance from the first wall of thereplacement contact side end plate, wherein said first predetermineddistance is greater than said second predetermined distance; andattaching the replacement contact side end plate to the cartridge body.8. A method of modifying an imaging process cartridge, the imagingprocess cartridge sized to be installed in a first type of imagingdevice and not sized to be installed in a second type of imaging device,the method comprising: providing the imaging process cartridgecomprising a cartridge body and a contact side end plate attached to thecartridge body, said contact side end plate comprising a generallyelongated shape having a generally curved first end and a generallyplanar second end, said generally planar second end comprising a firstwall and a second wall intersecting at right angles, said generallyplanar second end comprising an aperture in a third wall adapted forholding an axle of an organic photoconductor (OPC) drum and located at afirst predetermined distance from the first wall; removing the firstwall and a portion of the third wall to expose a fourth wall, at leastof portion of the fourth wall parallel to the first wall prior to theremoval of the first wall, wherein said aperture in the third walladapted for holding the axle of the OPC drum is located at a secondpredetermined distance from the first wall, wherein said firstpredetermined distance is greater than said second predetermineddistance;
 9. The method of claim 7 further comprising: removing aportion of the second wall.